Topology Optimization for Reducing Additive Manufacturing Processing Distortions

Report No. ARL-TR-8242
Authors: Raymond A Wildman, Andrew T Gaynor
Date/Pages: December 2017; 32 pages
Abstract: A method is presented for combining topology optimization with an approximate additive manufacturing process model so as to reduce thermal distortions induced during the build process. Thermal distortions are detrimental in any manufacturing process, though in some additive manufacturing processes these distortions may cause a build to completely fail. Here, 2 approximate manufacturing models are used in conjunction with a compliance minimization topology optimization problem. First, a quasi-static thermomechanical model is used that approximates distortions induced by the cooling of the material. Second, an element birth model is used in which elements are activated in turn, and a similar quasi-static thermomechanical problem is used at each step. The overall algorithm uses a compromise objective function to weight the 2 goals: thermal displacement minimization and compliance minimization. These models are compared along with a strict overhang constraint method.
Distribution: Approved for public release
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Last Update / Reviewed: December 1, 2017